Method of deforming a pattern and semiconductor device formed by utilizing deformed pattern

ABSTRACT

A method of deforming a pattern comprising the steps of: forming, over a substrate, a layered-structure with an upper surface including at least one selected region and at least a re-flow stopper groove, wherein the re-flow stopper groove extends outside the selected region and separate from the selected region; selectively forming at least one pattern on the selected region; and causing a re-flow of the pattern, wherein a part of an outwardly re-flowed pattern is flowed into the re-flow stopper groove, and then an outward re-flow of the pattern is restricted by the re-flow stopper groove extending outside of the pattern, thereby to form a deformed pattern with at least an outside edge part defined by an outside edge of the re-flow stopper groove.

This application is a division of application Ser. No. 10/300,735, filedon Nov. 21, 2002, now U.S. Pat. No. 6,953,976, which is a Divisional ofapplication Ser. No. 09/888,442, filed on Jun. 26, 2001, now U.S. Pat.No. 6,707,107 and application Ser. No. 09/888,442 is the parent ofDivisional application Ser. No. 10/201,132 filed on Jul. 24, 2002, theentire contents of which are hereby incorporated by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a method of deforming a resist patternto be used for forming a semiconductor device, and more particularly toa method of improving the accuracy in the quantity of deformation of anoriginal resist pattern or improving a highly accurate control to apattern shape of a reflow-deformed resist pattern.

2. Description of the Related Art

A conventional well known method of deforming the original resistpattern is a re-flow process by heating the original resist pattern. Aquantity of deformation of the resist pattern or a difference in size ofthe deformed resist pattern from the original resist pattern isrelatively small, for example, in the range of 0.5 micrometers to 3micrometers.

Another conventional well known method of deforming the original resistpattern is to dip the original resist pattern into chemicals or exposethe original resist pattern to a steam containing chemicals so that thechemicals osmose into the original resist pattern, whereby the originalresist pattern is dissolved and deformed. A quantity of deformation ofthe resist pattern or a difference in size of the deformed resistpattern from the original resist pattern is relatively large, forexample, in the range of 5 micrometers to 20 micrometers.

A high accuracy in the quantity of deformation of the resist pattern isdesired. In order to obtain the high accuracy in quantity of thedeformation, a highly accurate control to the quantity of deformation ofthe resist pattern is essential.

A conventional method of forming a thin film transistor utilizes theoriginal resist pattern and the deformed resist pattern. FIG. 1A is afragmentary plan view of a thin film transistor of a first step involvedin conventional sequential fabrication processes. FIG. 1B is afragmentary cross sectional elevation view of a thin film transistorshown in FIG. 1A, taken along a D–D′ line. FIG. 2A is a fragmentary planview of a thin film transistor of a second step involved in conventionalsequential fabrication processes. FIG. 2B is a fragmentary crosssectional elevation view of a thin film transistor shown in FIG. 2A,taken along a D–D′ line. FIG. 3A is a fragmentary plan view of a thinfilm transistor of a third step involved in conventional sequentialfabrication processes. FIG. 3B is a fragmentary cross sectionalelevation view of a thin film transistor shown in FIG. 3A, taken along aD–D′ line. FIG. 4A is a fragmentary plan view of a thin film transistorof a fourth step involved in conventional sequential fabricationprocesses. FIG. 4B is a fragmentary cross sectional elevation view of athin film transistor shown in FIG. 4A, taken along a D–D′ line. A thinfilm transistor is formed over an insulating substrate 301.

With reference to FIGS. 1A and 1B, a metal layer is formed on a topsurface of an insulating substrate 301. The metal layer is thenpatterned to form a gate electrode 302. A gate insulating film 303 isformed over the top surface of the insulating substrate 301 and over thegate electrode 302. An amorphous silicon film 304 is formed over thegate insulating film 303. An n+-type amorphous silicon film 305 isformed over the amorphous silicon film 304. A metal layer 306 is formedover the n+-type amorphous silicon film 305.

Thick resist masks 318 and thin resist masks 328 are selectively formedover the metal layer 306. The thick resist masks 318 are adjacent to achannel region 315. The thick resist masks 318 separates the thin resistmasks 328 from the channel region 315. The thick resist masks 318 have athickness of about 3 micrometers. The thin resist masks 328 have athickness of about 0.2–0.7 micrometers. Each pair of the thick resistmask 318 and the thin resist mask 328 comprises a unitary-formed resistmask which varies in thickness.

With reference to FIGS. 2A and 2B, a first anisotropic etching processis carried out by using the thick and thin resist masks 318 and 328 forselectively etching the metal layer 306 and the n+-type amorphoussilicon film 305, whereby the remaining parts of the n+-type amorphoussilicon film 305 become a source side ohmic contact layer 310 and adrain side ohmic contact layer 311, and further the remaining parts ofthe metal layer 306 become a source electrode 313 and a drain electrode314.

A plasma ashing process is carried out in the presence of O₂ plasma forreducing the thickness of the resist masks, whereby the thin resistmasks 328 are removed, while the thick resist masks 318 remain with areduced thickness. These thickness-reduced resist masks 318 willhereinafter be referred to as residual resist masks 338. The residualresist masks 338 are adjacent to the channel region 315. These residualresist masks 338 provide the original resist patterns.

With reference to FIGS. 3A and 3B, the residual resist masks 338 areexposed to a steam for 1–3 minutes, wherein the steam contains anorganic solvent, whereby the organic solvent gradually osmose into theresidual resist masks 338 as the original resist patterns, so that theoriginal resist pattern is dissolved and re-flowed, resulting in areflow-deformed resist pattern 348 being formed. The reflow-deformedresist pattern 348 extends to the channel region 315 and outside regionsof the residual resist masks 338 as the original resist patterns.

In the re-flow process, the residual resist masks 338 as the originalresist patterns are inwardly re-flowed toward the channel region 315 andthe re-flowed residual resist masks 338 come together over the channelregion 315. An interconnection 302′ connected to the gate electrode 302extends in a parallel direction to the line D–D′. This interconnection302′ forms a step-like barrier wall 317-a to stop the reflow of there-flowed residual resist masks 338, wherein the step-like barrier wall317-a extends in the parallel direction to the line D–D′. A furtherstep-like barrier wall 317-b is present, which extends in aperpendicular direction to the D–D′ line.

For this reason, the reflow of the residual resist masks 338 is stoppedbut only in two directions by the step-like barrier walls 317-a and 371b. The reflow of the residual resist masks 338 is free and not limitedin the remaining directions. It is difficult to control the reflow ofthe residual resist masks 338 in the remaining directions due to theabsence of any re-flow restrictor such as the step-like barrier walls317-a and 371 b. This means it difficult to control the pattern shape ofthe reflow-deformed resist mask 348.

With reference to FIGS. 4A and 4B, a second anisotropic etching processis carried out by use of the reflow-deformed resist mask 348 and thesource and drain electrodes 313 and 314 as masks for selectively etchingthe amorphous silicon film 304, whereby the remaining part of theamorphous silicon film 304 becomes an island layer 324. A pattern shapeof the island layer 324 is defined by the reflow-deformed resist mask348 in combination with additional masks of the source and drainelectrodes 313 and 314. The used reflow-deformed resist mask 348 isremoved. As a result, a reverse staggered thin film transistor isformed.

As described above, the pattern shape of the island layer 324 is definedby the reflow-deformed resist mask 348 in combination with additionalmasks of the source and drain electrodes 313 and 314. Further, it isdifficult to control the reflow of the residual resist masks 338 in theremaining directions due to the absence of any re-flow restrictor suchas the step-like barrier walls 317-a and 371 b. It is difficult tocontrol the pattern shape of the reflow-deformed resist mask 348. Thismeans it difficult to control the pattern shape of the island layer 324.The island layer 324 of amorphous silicon underlies the source and drainsides ohmic contact layers 310 and 311. The island layer 324 is thuselectrically connected to the source and drain electrodes 313 and 314. Aparasitic capacitance between the gate electrode 302 and the source anddrain electrodes 313 and 314 depends on the pattern shape of the islandlayer 324. In order to precisely control the parasitic capacitance, itis essential to control the pattern shape of the reflow-deformed resistmask 348 or to control the pattern shape of the island layer 324.

In the above circumstances, the development of a novel improving ahighly accurate control to a pattern shape of a reflow-deformed resistpattern free from the above problems is desirable.

SUMMARY OF THE INVENTION

Accordingly, it is an object of the present invention to provide a novelmethod of deforming a resist pattern to be used for forming asemiconductor device free from the above problems.

It is a further object of the present invention to provide a novelmethod of improving the accuracy in the quantity of deformation of anoriginal resist pattern.

It is a still further object of the present invention to provide a novelmethod improving a highly accurate control to a pattern shape of areflow-deformed resist pattern.

It is yet a further object of the present invention to provide a novelmethod of patterning a layer by use of a deformed resist pattern from anoriginal resist pattern.

It is yet a further object of the present invention to provide a novelmethod of forming a semiconductor device by use of both original anddeformed resist patterns in different processes.

It is a further primary object of the present invention to provide asemiconductor device formed by utilizing a novel method of deforming aresist pattern.

It is another object of the present invention to provide a semiconductordevice formed by utilizing a novel method of improving the accuracy inthe quantity of deformation of an original resist pattern.

It is still another object of the present invention to provide asemiconductor device formed by utilizing a novel method improving ahighly accurate control to a pattern shape of a reflow-deformed resistpattern.

It is yet another object of the present invention to provide asemiconductor device formed by utilizing a novel method of patterning alayer by use of a deformed resist pattern from an original resistpattern.

It is further another object of the present invention to provide asemiconductor device formed by utilizing a novel method of forming asemiconductor device by use of both original and deformed resistpatterns in different processes.

The present invention provides a method of deforming a patterncomprising the steps of: forming, over a substrate, a layered-structurewith an upper surface including at least one selected region and atleast a re-flow stopper groove, wherein the re-flow stopper grooveextends outside the selected region and separate from the selectedregion; selectively forming at least one pattern on the selected region;and causing a re-flow of the pattern, wherein a part of an outwardlyre-flowed pattern is flowed into the re-flow stopper groove, and then anoutward re-flow of the pattern is restricted by the re-flow stoppergroove extending outside of the pattern, thereby to form a deformedpattern with at least an outside edge part defined by an outside edge ofthe re-flow stopper groove.

The above and other objects, features and advantages of the presentinvention will be apparent from the following descriptions.

BRIEF DESCRIPTION OF THE DRAWINGS

Preferred embodiments according to the present invention will bedescribed in detail with reference to the accompanying drawings.

FIG. 1A is a fragmentary plan view of a thin film transistor of a firststep involved in conventional sequential fabrication processes.

FIG. 1B is a fragmentary cross sectional elevation view of a thin filmtransistor shown in FIG. 1A, taken along a D–D′ line.

FIG. 2A is a fragmentary plan view of a thin film transistor of a secondstep involved in conventional sequential fabrication processes.

FIG. 2B is a fragmentary cross sectional elevation view of a thin filmtransistor shown in FIG. 2A, taken along a D–D′ line.

FIG. 3A is a fragmentary plan view of a thin film transistor of a thirdstep involved in conventional sequential fabrication processes.

FIG. 3B is a fragmentary cross sectional elevation view of a thin filmtransistor shown in FIG. 3A, taken along a D–D′ line.

FIG. 4A is a fragmentary plan view of a thin film transistor of a fourthstep involved in conventional sequential fabrication processes.

FIG. 4B is a fragmentary cross sectional elevation view of a thin filmtransistor shown in FIG. 4A, taken along a D–D′ line.

FIG. 5A is a fragmentary plan view of a thin film transistor of a firststep involved in novel sequential fabrication processes in a firstembodiment in accordance with the present invention.

FIG. 5B is a fragmentary cross sectional elevation view of a thin filmtransistor shown in FIG. 5A, taken along an A–A′ line.

FIG. 6A is a fragmentary plan view of a thin film transistor of a secondstep involved in novel sequential fabrication processes in a firstembodiment in accordance with the present invention.

FIG. 6B is a fragmentary cross sectional elevation view of a thin filmtransistor shown in FIG. 6A, taken along an A–A′ line.

FIG. 7A is a fragmentary plan view of a thin film transistor of a thirdstep involved in novel sequential fabrication processes in a firstembodiment in accordance with the present invention.

FIG. 7B is a fragmentary cross sectional elevation view of a thin filmtransistor shown in FIG. 7A, taken along an A–A′ line.

FIG. 8A is a fragmentary plan view of a thin film transistor of a fourthstep involved in novel sequential fabrication processes in a firstembodiment in accordance with the present invention.

FIG. 8B is a fragmentary cross sectional elevation view of a thin filmtransistor shown in FIG. 8A, taken along an A–A′ line.

FIG. 9A is a fragmentary plan view of a thin film transistor of a thirdstep involved in novel sequential fabrication processes in a firstmodification to the first embodiment in accordance with the presentinvention.

FIG. 9B is a fragmentary cross sectional elevation view of a thin filmtransistor shown in FIG. 9A, taken along an A–A′ line.

FIG. 10A is a fragmentary plan view of a thin film transistor of a firststep involved in novel sequential fabrication processes in a secondembodiment in accordance with the present invention.

FIG. 10B is a fragmentary cross sectional elevation view of a thin filmtransistor shown in FIG. 10A, taken along an A–A′ line.

FIG. 11A is a fragmentary plan view of a thin film transistor of asecond step involved in novel sequential fabrication processes in asecond embodiment in accordance with the present invention.

FIG. 11B is a fragmentary cross sectional elevation view of a thin filmtransistor shown in FIG. 11A, taken along an A–A′ line.

FIG. 12A is a fragmentary plan view of a thin film transistor of a thirdstep involved in novel sequential fabrication processes in a secondembodiment in accordance with the present invention.

FIG. 12B is a fragmentary cross sectional elevation view of a thin filmtransistor shown in FIG. 12A, taken along an A–A′ line.

FIG. 13A is a fragmentary plan view of a thin film transistor of afourth step involved in novel sequential fabrication processes in asecond embodiment in accordance with the present invention.

FIG. 13B is a fragmentary cross sectional elevation view of a thin filmtransistor shown in FIG. 13A, taken along an A–A′ line.

FIG. 14A is a fragmentary plan view of a thin film transistor of a thirdstep involved in novel sequential fabrication processes in a firstmodification to the second embodiment in accordance with the presentinvention.

FIG. 14B is a fragmentary cross sectional elevation view of a thin filmtransistor shown in FIG. 14A, taken along an A–A′ line.

FIG. 15A is a fragmentary plan view of a thin film transistor of a firststep involved in novel sequential fabrication processes in a thirdembodiment in accordance with the present invention.

FIG. 15B is a fragmentary cross sectional elevation view of a thin filmtransistor shown in FIG. 15A, taken along an A–A′ line.

FIG. 16A is a fragmentary plan view of a thin film transistor of asecond step involved in novel sequential fabrication processes in athird embodiment in accordance with the present invention.

FIG. 16B is a fragmentary cross sectional elevation view of a thin filmtransistor shown in FIG. 16A, taken along an A–A′ line.

FIG. 17A is a fragmentary plan view of a thin film transistor of a thirdstep involved in novel sequential fabrication processes in a thirdembodiment in accordance with the present invention.

FIG. 17B is a fragmentary cross sectional elevation view of a thin filmtransistor shown in FIG. 17A, taken along a B–B′ line.

FIG. 18A is a fragmentary plan view of a thin film transistor of a firststep involved in novel sequential fabrication processes in a fourthembodiment in accordance with the present invention.

FIG. 18B is a fragmentary cross sectional elevation view of a thin filmtransistor shown in FIG. 18A, taken along a C–C′ line.

FIG. 19A is a fragmentary plan view of a thin film transistor of asecond step involved in novel sequential fabrication processes in afourth embodiment in accordance with the present invention.

FIG. 19B is a fragmentary cross sectional elevation view of a thin filmtransistor shown in FIG. 19A, taken along a C–C′ line.

FIG. 20A is a fragmentary plan view of a thin film transistor of a thirdstep involved in novel sequential fabrication processes in a fourthembodiment in accordance with the present invention.

FIG. 20B is a fragmentary cross sectional elevation view of a thin filmtransistor shown in FIG. 20A, taken along a C–C′ line.

FIG. 21A is a fragmentary plan view of a thin film transistor of a firststep involved in novel sequential fabrication processes in a fifthembodiment in accordance with the present invention.

FIG. 21B is a fragmentary cross sectional elevation view of a thin filmtransistor shown in FIG. 21A, taken along an E–E′ line.

FIG. 22A is a fragmentary plan view of a thin film transistor of asecond step involved in novel sequential fabrication processes in afifth embodiment in accordance with the present invention.

FIG. 22B is a fragmentary cross sectional elevation view of a thin filmtransistor shown in FIG. 22A, taken along an E–E′ line.

FIG. 23A is a fragmentary plan view of a thin film transistor of a thirdstep involved in novel sequential fabrication processes in a fifthembodiment in accordance with the present invention.

FIG. 23B is a fragmentary cross sectional elevation view of a thin filmtransistor shown in FIG. 23A, taken along an E–E′ line.

FIG. 24A is a fragmentary plan view of a thin film transistor of afourth step involved in novel sequential fabrication processes in afifth embodiment in accordance with the present invention.

FIG. 24B is a fragmentary cross sectional elevation view of a thin filmtransistor shown in FIG. 24A, taken along an E–E′ line.

FIG. 25A is a fragmentary plan view of a thin film transistor of a thirdstep involved in novel sequential fabrication processes in a firstmodification to the fifth embodiment in accordance with the presentinvention.

FIG. 25B is a fragmentary cross sectional elevation view of a thin filmtransistor shown in FIG. 25A, taken along an F–F′ line.

FIG. 26A is a fragmentary plan view of a thin film transistor of a thirdstep involved in novel sequential fabrication processes in a secondmodification to the fifth embodiment in accordance with the presentinvention.

FIG. 26B is a fragmentary cross sectional elevation view of a thin filmtransistor shown in FIG. 26A, taken along an F–F′ line.

FIG. 27A is a fragmentary plan view of a thin film transistor of a thirdstep involved in novel sequential fabrication processes in a thirdmodification to the fifth embodiment in accordance with the presentinvention.

FIG. 27B is a fragmentary cross sectional elevation view of a thin filmtransistor shown in FIG. 27A, taken along an F–F′ line.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

A first aspect of the present invention is a method of deforming apattern. The method comprises the steps of: forming, over a substrate, alayered-structure with an upper surface including at least one selectedregion and at least a re-flow stopper groove, wherein the re-flowstopper groove extends outside the selected region and separate from theselected region; selectively forming at least one pattern on theselected region; and causing a re-flow of the pattern, wherein a part ofan outwardly re-flowed pattern is flowed into the re-flow stoppergroove, and then an outward re-flow of the pattern is restricted by there-flow stopper groove extending outside of the pattern, thereby to forma deformed pattern with at least an outside edge part defined by anoutside edge of the re-flow stopper groove.

It is preferable that the re-flow stopper groove excludes a channelregion, and parts of the outwardly re-flowed pattern are flowed intoboth the re-flow stopper groove and the channel region.

It is further preferable that the re-flow stopper groove is separatefrom the channel region.

It is further more preferable that the re-flow stopper groove ispositioned indirectly over a gap between a gate electrode and at least adummy gate electrode.

It is also preferable that the re-flow stopper groove comprises arecessed trench groove formed in the layered-structure.

It is also preferable that the re-flow stopper groove comprises a firstgap between a source electrode and a dummy source electrode and a secondgap between a drain electrode and a dummy drain electrode.

It is also preferable that the re-flow stopper groove is adjacent to thechannel region.

It is further preferable that the re-flow stopper groove is positionedindirectly over a gap between a gate electrode and at least a dummy gateelectrode.

It is further preferable that the re-flow stopper groove is defined byboth a side wall of an extending layer from one of source and drainelectrodes and a stepped portion of the channel region, where thestepped portion is positioned indirectly over an edge of a gateelectrode.

It is also preferable that the re-flow stopper groove includes a channelregion, and a part of the outwardly re-flowed pattern is flowed into there-flow stopper groove.

It is further preferable that the re-flow stopper groove and the channelregion are in forms of annular shape, and an outside peripheral edge ofthe re-flow stopper groove encompasses an outside peripheral edge of thechannel region, and the outside peripheral edge of the re-flow stoppergroove is defined by stepped portions of source and drain electrodes,where the stepped portions of the source and drain electrodes arepositioned indirectly over a stepped portion of a gate electrode, andwhere the stepped portion of the gate electrode extends in a form ofannular shape and defines a depressed region of the gate electrode.

It is also preferable that the re-flow stopper groove is included in achannel region which extends outside the selected region, and a part ofthe outwardly re-flowed pattern is flowed into the channel region.

It is further preferable that the re-flow stopper groove is positionedindirectly over a groove of a gate electrode.

It is also preferable that the re-flow stopper groove just overlaps achannel region which extends outside the selected region, and a part ofthe outwardly re-flowed pattern is flowed into the re-flow stoppergroove.

It is also preferable that the re-flow stopper groove and the channelregion are an annular shaped region which is defined by an island-shapedelectrode and an annular-shaped electrode which surrounds theisland-shaped electrode completely.

It is also preferable that the re-flow stopper groove surrounds theselected region completely.

It is also preferable that the re-flow stopper groove surrounds theselected region incompletely.

It is also preferable that the selected region comprises a set of pluralselected regions separate from each other and adjacent to each other,and the re-flow stopper groove surrounds the set of plural selectedregions completely.

It is also preferable that the selected region comprises a set of pluralselected regions separate from each other and adjacent to each other,and the re-flow stopper groove surrounds the set of plural selectedregions incompletely.

It is also preferable that the pattern is: a pattern containing anorganic material.

It is further preferable that the pattern is a resist pattern.

A second aspect of the present invention is a method of forming are-flowed pattern over a layered-structure. The method comprises thesteps of: forming an original resist pattern over a layered-structurewith an upper surface including at least one selected region and atleast a re-flow stopper groove wherein extends outside the selectedregion and separate from the selected region, and the original resistpattern comprising a thicker portion and a thinner portion, and thethicker portion extending on a selected region, patterning alayered-structure by use of the original resist pattern; removing thethinner portion and reducing a thickness of the thicker portion to forma residual resist pattern unchanged in pattern shape from the thickerportion; and causing a re-flow of the residual pattern, wherein a partof an outwardly re-flowed pattern is flowed into the re-flow stoppergroove, and then an outward re-flow of the pattern is restricted by there-flow stopper groove extending outside of the pattern, thereby to forma deformed pattern with at least an outside edge part defined by anoutside edge of the re-flow stopper groove.

A third aspect of the present invention is a method of patterning alayered-structure. The method comprises the steps of: forming anoriginal resist pattern over a layered-structure with an upper surfaceincluding at least one selected region and at least a re-flow stoppergroove wherein extends outside the selected region and separate from theselected region, and the original resist pattern comprising a thickerportion and a thinner portion, and the thicker portion extending on aselected region, patterning a layered-structure by use of the originalresist pattern; removing the thinner portion and reducing a thickness ofthe thicker portion to form a residual resist pattern unchanged inpattern shape from the thicker portion; and causing a re-flow of theresidual pattern, wherein a part of an outwardly re-flowed pattern isflowed into the re-flow stopper groove, and then an outward re-flow ofthe pattern is restricted by the re-flow stopper groove extendingoutside of the pattern, thereby to form a deformed pattern with at leastan outside edge part defined by an outside edge of the re-flow stoppergroove; and patterning the layered-structure by use of the deformedpattern.

A fourth aspect of the present invention is a semiconductor deviceincluding gate, source and drain electrodes, a layered structure over asubstrate, and the layered structure has a surface which further has atleast a groove, wherein the groove extends outside at least a selectedregion on the layered-structure, and the selected region being adjacentto a channel region, and the groove extends outside of the gateelectrode, and the groove is separate by a gap from the gate electrode.

It is preferable that the groove surrounds the gate electrodeincompletely.

It is also preferable that the groove surrounds the gate electrodecompletely.

It is further preferable that the groove extends in an annular form.

A fifth aspect of the present invention is a semiconductor deviceincluding gate, source and drain electrodes, a layered structure over asubstrate, and at least a groove formed in the layered structure,wherein the groove extends outside at least a selected region on thelayered-structure, and the selected region being adjacent to a channelregion, and the groove extends outside of the gate electrode, and thegroove is separate by a gap from the gate electrode.

It is also preferable that the groove surrounds the gate electrodeincompletely.

It is also preferable that the groove surrounds the gate electrodecompletely.

It is also preferable that the groove extends in an annular form.

A sixth aspect of the present invention is a semiconductor deviceincluding a gate electrode and a layered-structure, wherein the gateelectrode has at least a step, and an upper surface of thelayered-structure also has at least a step which is positioned over thestep of the gate electrode.

It is also preferable that the gate has a thickness-reduced regionbounded by the step.

A seventh aspect of the present invention is a semiconductor deviceincluding a gate electrode structure which further comprises at least agate electrode and at least a dummy gate electrode, wherein the dummygate electrode is separate by a gap from the gate electrode andpositioned outside of the gate electrode.

It is also preferable that the dummy gate electrode surrounds the gateelectrode incompletely.

It is also preferable that the dummy gate electrode surrounds the gateelectrode completely.

It is also preferable that the dummy gate electrode extends in anannular form.

It is also preferable that the dummy gate electrode extends adjacent toand parallel to a flat side of the gate electrode.

It is also preferable that the semiconductor device further includes amulti-layer structure comprising plural laminated layers which extendover the gate electrode structure, and surfaces of the plural laminatedlayers have grooves which are positioned over the gap.

An eighth aspect of the present invention is a semiconductor deviceincluding gate, source and drain electrodes, a layered structure over asubstrate, and at least a groove in the layered structure, wherein thegroove extends outside at least a selected region on thelayered-structure, and the selected region being adjacent to a channelregion, and the groove extends outside of the gate electrode, and thegroove is separate by a gap from the gate electrode, and wherein atleast a part of the source and drain electrodes is present in thegroove.

It is also preferable that the groove surrounds the gate electrodeincompletely.

It is also preferable that the groove surrounds the gate electrodecompletely.

It is also preferable that the groove extends in an annular form.

It is also preferable that the groove extends adjacent to and parallelto a flat side of the gate electrode.

A ninth aspect of the present invention is a semiconductor deviceincluding gate, source and drain electrodes, dummy source and drainelectrodes, a layered structure over a substrate, and at least a groove,wherein the dummy source and drain electrodes are positioned outside thesource and drain electrodes, and the groove separates the source anddrain electrodes from the dummy source and drain electrodes, and whereinthe groove extends outside at least a selected region on thelayered-structure, and the selected region being adjacent to a channelregion, and the groove extends outside of the gate electrode in planview, and the groove is separate from the gate electrode in plan view.

It is also preferable that the groove surrounds the gate electrodeincompletely.

It is also preferable that the groove surrounds the gate electrodecompletely.

It is also preferable that the groove extends in an annular form.

It is also preferable that the groove extends adjacent to and parallelto a flat side of the gate electrode.

A tenth aspect of the present invention is a semiconductor deviceincluding gate, source and drain electrodes, a channel region, and atleast a groove, wherein first one of the source and drain electrodesincludes an island portion, and second one of the source and drainelectrodes includes a surrounding portion which surrounds the channelregion, and the channel region further surrounds the island portion, andthe surrounding portion is separate by the channel region from theisland portion, and wherein the groove includes the channel region.

It is also preferable that the surrounding portion surrounds the islandportion incompletely.

It is also preferable that the groove further includes an additionalgroove which extends adjacent to an opening side of the surroundingportion.

It is also preferable to further comprise a dummy gate electrodeseparate by a gap from the gate electrode, wherein the additional grooveis positioned over the gap.

It is also preferable that the first one further includes a connectingportion, and an additional extending portion which extends adjacent toan opening side of the surrounding portion and which faces to theopening side, and the additional extending portion is connected throughthe connecting portion to the island portion.

It is also preferable that the connecting portion has a step-like wall.

It is also preferable that the surrounding portion surrounds the islandportion completely.

It is also preferable that the groove extends in an annular form.

An eleventh aspect of the present invention is a semiconductor deviceincluding a layered-structure over a substrate, wherein an upper surfaceof the substrate has at least a groove, and an upper surface of thelayered-structure also has at least a groove which is positioned overthe groove of the substrate, and wherein the groove of the substrateselectively extends adjacent to a channel region.

It is also preferable that the groove of the substrate extends aroundthe channel region in plan view.

It is also preferable that the groove of the substrate surroundscompletely.

It is also preferable that the groove of the substrate surroundsincompletely.

A twelfth aspect of the present invention is a semiconductor deviceincluding a layered-structure over a substrate, wherein an upper surfaceof the substrate has at least a level-down region, and an upper surfaceof the layered-structure also has at least a groove which extends overthe level-down region of the substrate, and wherein the level-downregion of the substrate selectively extends including a channel regionin plan view.

FIRST EMBODIMENT

A first embodiment according to the present invention will be describedin detail with reference to the drawings. FIG. 5A is a fragmentary planview of a thin film transistor of a first step involved in novelsequential fabrication processes in a first embodiment in accordancewith the present invention. FIG. 5B is a fragmentary cross sectionalelevation view of a thin film transistor shown in FIG. 5A, taken alongan A–A′ line. FIG. 6A is a fragmentary plan view of a thin filmtransistor of a second step involved in novel sequential fabricationprocesses in a first embodiment in accordance with the presentinvention. FIG. 6B is a fragmentary cross sectional elevation view of athin film transistor shown in FIG. 6A, taken along an A–A′ line. FIG. 7Ais a fragmentary plan view of a thin film transistor of a third stepinvolved in novel sequential fabrication processes in a first embodimentin accordance with the present invention. FIG. 7B is a fragmentary crosssectional elevation view of a thin film transistor shown in FIG. 7A,taken along an A–A′ line. FIG. 8A is a fragmentary plan view of a thinfilm transistor of a fourth step involved in novel sequentialfabrication processes in a first embodiment in accordance with thepresent invention. FIG. 8B is a fragmentary cross sectional elevationview of a thin film transistor shown in FIG. 8A, taken along an A–A′line. A thin film transistor is formed over an insulating substrate 1.

With reference to FIGS. 5A and 5B, a bottom conductive film is formedover a top surface of the insulating substrate 1. The bottom conductivefilm is patterned to form a gate electrode interconnection 2 and a dummygate electrode 12. The gate electrode interconnection 2 has a gateelectrode 2 which has a rectangle shape in plan view. The gate electrode2 extends from the gate electrode interconnection 2 in a directionperpendicular to a longitudinal direction of the gate electrodeinterconnection 2. The dummy gate electrode 12 is generally U-shaped, sothat the dummy gate electrode 12 surrounds the rectangle-shaped gateelectrode 2. The dummy gate electrode 12 is separate from the gateelectrode 2 and from the gate electrode interconnection 2. One side ofthe gate electrode 2 is bounded with the gate electrode interconnection2. The dummy gate electrode 12 extends along the remaining three sidesof the gate electrode 2. An U-shaped gap is defined between inside edgesof the dummy gate electrode 12 and the remaining three sides of the gateelectrode 2. The U-shaped gap has an uniform width and is formed betweenthe gate electrode 2 and the dummy gate electrode 12.

A gate insulating film 3 having a thickness of 3500 nanometers is formedover the insulating substrate 1 and the gate electrode interconnection2, the gate electrode 2 and the dummy gate electrode 12, wherein thegate insulating film 3 fills the U-shaped gap between inside edges ofthe dummy gate electrode 12 and the remaining three sides of the gateelectrode 2. An upper surface of the gate insulating film 3 has a groovewhich extends in a form of generally U-shape in plan view. The grooveextends over the U shaped gap between the gate electrode 2 and the dummygate electrode 12. The groove in the upper surface of the gateinsulating film 3 is thus formed by the U-shaped gap between the gateelectrode 2 and the dummy gate electrode 12.

An amorphous silicon film 4 having a thickness of 200 nanometers isformed over the upper surface of the gate insulating film 3. An uppersurface of the amorphous silicon film 4 also has a groove which extendsin a form of generally U-shape in plan view. The groove extends over theU-shaped groove in the upper surface of the gate insulating film 3.

An n+-type amorphous silicon film 5 having a thickness of 50 nanometersis formed over the upper surface of the amorphous silicon film 4. Anupper surface of the n+-type amorphous silicon film 5 also has a groovewhich extends in a form of generally U-shape in plan view. The grooveextends over the U-shaped groove in the upper surface of the amorphoussilicon film 4.

A top conductive film 6 is formed over the upper surface of the n+-typeamorphous silicon film 5. An upper surface of the top conductive film 6also has a reflow stopper groove 7 which extends in a form of generallyU-shape in plan view. The reflow stopper groove 7 extends over theU-shaped groove in the upper surface of the n+-type amorphous siliconfilm 5. The reflow stopper groove 7 is positioned indirectly over theU-shaped gap between the gate electrode 2 and the dummy gate electrode12.

A resist mask 8 is selectively formed over the upper surface of the topconductive film 6 by use of a lithography technique. The resist mask 8comprises a thick resist mask 18 and a thin resist mask 28. The thickresist mask 18 is positioned in selected regions adjacent to a channelregion 15 which has a rectangle shape. The selected regions also haverectangle shape regions along opposite outsides of the rectangle shapechannel region 15. The thick resist mask 18 may have a thickness ofabout 3 micrometers. The thin resist mask 28 may have a thickness ofabout 0.2–0.7 micrometers.

With reference to FIGS. 6A and 6B, a first etching process is carriedout by use of the thick and thin resist masks 18 and 28 for selectivelyetching the top conductive film 6 and the n+-type amorphous silicon film5. The top conductive film 6 may comprise a metal film. The topconductive film 6 may selectively be etched by a wet etching process toform source and drain electrodes 13 and 14. The n+-type amorphoussilicon film 5 may also selectively be etched by a dry etching processunder a pressure of 10 Pa, at a power of 1000 W for 60 seconds, whereinsource gas flow rate ratios of SF₆/HCl/He are 100/100/150 sccm to formohmic contact layers 10 and 11 which underlie the source and drainelectrodes 13 and 14, thereby making ohmic contacts between theamorphous silicon film 4 and the source and drain electrodes 13 and 14.

Subsequently, a plasma ashing process is carried out in the presence ofplasma atmosphere with oxygen flow rate at 400 sccm under a pressure of20 Pa, and an RF power of 1000 W for 120 seconds. This plasma ashingprocess reduces the thickness of the resist mask 8, whereby the thinresist mask 28 is removed whilst the thick resist mask 18 is reduced inthickness, whereby the thickness-reduced resist mask 18 becomes aresidual resist mask 38 which extends on the selected regions adjacentto the channel region 15.

With reference to FIGS. 7A and 7B, the residual resist mask 38 is thenexposed to a steam of a solution which contains an organic solvent suchas ethylcellsolveacetate (ECA) or N-methyl-2-pyrolidinone at 27° C. for1–3 minutes. This exposure process causes the organic solvent to osmoseinto the residual resist mask 38, whereby the residual resist mask 38 isdissolved and re-flowed, and the residual resist mask 38 becomes areflow-deformed resist mask 48.

A part of the re-flowed resist mask 48 is dropped into the channelregion 15 and other parts of the re-flowed resist mask 48 are droppedinto the reflow stopper groove 7 which extends in a form of thegenerally U-shape and positioned indirectly over the U-shaped gapbetween the gate electrode 2 and the dummy gate electrode 12. An inwardreflow of the resist mask 48 is dropped into the channel region 15 and afurther inward reflow of the resist mask 48 is restricted by the channelregion 15. An outward reflow of the resist mask 48 is omnidirectional.The outward reflow of the resist mask 48 in one direction toward astep-like barrier wall 17 which extends indirectly over an edge of thegate electrode interconnection 2 is stopped or restricted by thestep-like barrier wall 17. The remaining outward reflow of the resistmask 48 in the remaining three directions toward the reflow stoppergroove 7 is dropped into the reflow stopper groove 7 and stopped orrestricted by the reflow stopper groove 7. Each gap between ends of thereflow stopper groove 7 and the step-like barrier wall 17 is so narrowas substantially restricting a further outward reflow of the resist mask48. An external shape or a circumferential shape of the reflow-deformedresist mask 48 provides a pattern shape. The external shape or acircumferential shape of the reflow-deformed resist mask 48 is definedby the step-like barrier wall 17 and outside edges of the reflow stoppergroove 7. The step-like barrier wall 17 and the reflow stopper groove 7enable a highly accurate control or definition to the pattern shape ofthe reflow-deformed resist mask 48. As long as the positions of thestep-like barrier wall 17 and the reflow stopper groove 7 are highlyaccurate, the pattern shape of the reflow-deformed resist mask 48 isalso highly accurate. Since the highly accurate positioning of thestep-like barrier wall 17 and the reflow stopper groove 7 is relativelyeasy by use of the known techniques, it is also relatively easy toobtain the desired highly accurate control or definition to the patternshape of the reflow-deformed resist mask 48.

With reference to FIGS. 8A and 8B, a second etching process is carriedout by use of the deformed resist mask 48 in combination with the sourceand drain electrodes 13 and 14 as combined masks for selectively etchingthe amorphous silicon film 4, whereby the amorphous silicon film 4becomes an island layer 24 which has a pattern shape which is defined bythe deformed resist mask 48 in combination with the source and drainelectrodes 13 and 14 as combined masks. The used deformed resist mask 48is then removed, whereby a thin film transistor is formed.

The island layer 24 of amorphous silicon underlies the ohmic contactlayers 10 and 11. The island layer 24 is thus electrically connected tothe source and drain electrodes 13 and 14. A parasitic capacitancebetween the gate electrode 2 and the source and drain electrodes 13 and14 depends on the pattern shape of the island layer 24. Since it ispossible to obtain a highly accurate control or definition to thepattern shape of the reflow-deformed resist mask 48 or the pattern shapeof the island layer 24, it is possible to obtain a highly accuratecontrol to the parasitic capacitance.

In the above described embodiment, the reflow of the residual resistfilm 38 is caused by exposing the residual resist film 38 to the steamwhich contains the solution containing the organic solvent. Any otherknow methods for causing the re-flow of the resist mask are, of course,available. The re-flow may be caused by applying a heat to the resistmask.

The above novel method is further applicable to deformation to otherpattern film than the resist mask, provided the pattern is allowed to bere-flowed by any available measures.

The above described novel method of the first embodiment may be modifiedas follows. FIG. 9A is a fragmentary plan view of a thin film transistorof a third step involved in novel sequential fabrication processes in afirst modification to the first embodiment in accordance with thepresent invention. FIG. 9B is a fragmentary cross sectional elevationview of a thin film transistor shown in FIG. 9A, taken along an A–A′line.

The following descriptions will focus on the difference of the firstmodified method from the above novel method of the first embodiment. Inthe above novel method of the first embodiment, the dummy gate electrode12 is separate from the gate electrode interconnection 2. In this firstmodified method, a dummy gate electrode 22 is connected with the gateelectrode interconnection 2.

The dummy gate electrode 22 is generally U-shaped, so that the dummygate electrode 22 surrounds the rectangle-shaped gate electrode 2. Thedummy gate electrode 12 is separate from the gate electrode 2 butconnected with the gate electrode interconnection 2. One side of thegate electrode 2 is bounded with the gate electrode interconnection 2.The dummy gate electrode 22 extends along the remaining three sides ofthe gate electrode 2. An U-shaped gap is defined between inside edges ofthe dummy gate electrode 22 and the remaining three sides of the gateelectrode 2. The U-shaped gap has an uniform width and is formed betweenthe gate electrode 2 and the dummy gate electrode 22.

An upper surface of the top conductive film 6 also has a reflow stoppergroove 27 which extends in a form of generally U-shape in plan view. Thereflow stopper groove 27 extends over the U-shaped groove in the uppersurface of the n+-type amorphous silicon film 5. The reflow stoppergroove 27 is positioned indirectly over the U-shaped gap between thegate electrode 2 and the dummy gate electrode 22.

In the re-flow process, a part of the re-flowed resist mask 58 isdropped into the channel region 15 and other parts of the re-flowedresist mask 58 are dropped into the reflow stopper groove 27 whichextends in a form of the generally U-shape and positioned indirectlyover the U-shaped gap between the gate electrode 2 and the dummy gateelectrode 22. An inward reflow of the resist mask 58 is dropped into thechannel region 15 and a further inward reflow of the resist mask 58 isrestricted by the channel region 15. An outward reflow of the resistmask 58 is omnidirectional. The outward reflow of the resist mask 58 inone direction toward a step-like barrier wall 17 which extendsindirectly over an edge of the gate electrode interconnection 2 isstopped or restricted by the step-like barrier wall 17. The remainingoutward reflow of the resist mask 58 in the remaining three directionstoward the reflow stopper groove 7 is dropped into the reflow stoppergroove 27 and stopped or restricted by the reflow stopper groove 27. Nogap is formed between ends of the reflow stopper groove 7 and thestep-like barrier wall 17, whereby complete restriction of a furtheroutward reflow of the resist mask 58 is obtained. An external shape or acircumferential shape of the reflow-deformed resist mask 58 provides apattern shape. The external shape or a circumferential shape of thereflow-deformed resist mask 58 is defined by the step-like barrier wall17 and outside edges of the reflow stopper groove 27. The step-likebarrier wall 17 and the reflow stopper groove 27 enable a highlyaccurate control or definition to the pattern shape of thereflow-deformed resist mask 58. As long as the positions of thestep-like barrier wall 17 and the reflow stopper groove 27 are highlyaccurate, the pattern shape of the reflow-deformed resist mask 58 isalso highly accurate. Since the highly accurate positioning of thestep-like barrier wall 17 and the reflow stopper groove 27 is relativelyeasy by use of the known techniques, it is also relatively easy toobtain the desired highly accurate control or definition to the patternshape of the reflow-deformed resist mask 58.

SECOND EMBODIMENT

A second embodiment according to the present invention will be describedin detail with reference to the drawings. FIG. 10A is a fragmentary planview of a thin film transistor of a first step involved in novelsequential fabrication processes in a second embodiment in accordancewith the present invention. FIG. 10B is a fragmentary cross sectionalelevation view of a thin film transistor shown in FIG. 10A, taken alongan A–A′ line. FIG. 11A is a fragmentary plan view of a thin filmtransistor of a second step involved in novel sequential fabricationprocesses in a second embodiment in accordance with the presentinvention. FIG. 11B is a fragmentary cross sectional elevation view of athin film transistor shown in FIG. 11A, taken along an A–A′ line. FIG.12A is a fragmentary plan view of a thin film transistor of a third stepinvolved in novel sequential fabrication processes in a secondembodiment in accordance with the present invention. FIG. 12B is afragmentary cross sectional elevation view of a thin film transistorshown in FIG. 12A, taken along an A–A′ line. FIG. 13A is a fragmentaryplan view of a thin film transistor of a fourth step involved in novelsequential fabrication processes in a second embodiment in accordancewith the present invention. FIG. 13B is a fragmentary cross sectionalelevation view of a thin film transistor shown in FIG. 13A, taken alongan A–A′ line. A thin film transistor is formed over an insulatingsubstrate 101.

With reference to FIGS. 10A and 10B, a bottom conductive film is formedover a top surface of the insulating substrate 101. The bottomconductive film is patterned to form a gate electrode interconnection102. The gate electrode interconnection 102 has a gate electrode 102which has a rectangle shape in plan view. The gate electrode 102 extendsfrom the gate electrode interconnection 102 in a direction perpendicularto a longitudinal direction of the gate electrode interconnection 102.

A gate insulating film 103 is formed over the insulating substrate 101and the gate electrode interconnection 102, and the gate electrode 102.An amorphous silicon film 104 is formed over the upper surface of thegate insulating film 103. An n+-type amorphous silicon film 105 isformed over the upper surface of the amorphous silicon film 104.

The n+-type amorphous silicon film 105, the amorphous silicon film 104and the gate insulating film 103 are selectively etched to form a trenchgroove 109 which extends in a form of generally U-shape in plan view. Abottom of the trench groove 109 comprises a part of the top surface ofthe insulating substrate 101. The trench groove 109 is generallyU-shaped, so that the trench groove 109 surrounds the rectangle-shapedgate electrode 102. The trench groove 109 is separate from the gateelectrode 102 and from the gate electrode interconnection 102. One sideof the gate electrode 102 is bounded with the gate electrodeinterconnection 102. The trench groove 109 extends along the remainingthree sides of the gate electrode 102. The trench groove 109 extendsoutside the gate electrode 102. The trench groove 109 has an uniformwidth.

With reference to FIGS. 11A and 11B, a conductive film 106 is entirelyformed over the upper surface of the n+-type amorphous silicon film 105and in the trench groove 109, wherein the bottom and side walls of thetrench groove 109 are covered by the conductive film 106, but the trenchgroove 109 is not filled with the conductive film 106, whereby a reflowstopper groove 107 is formed in the trench groove 109. Namely, an uppersurface of the conductive film 106 also has a reflow stopper groove 107which extends in a form of generally U-shape in plan view. The reflowstopper groove 107 extends overlaps the U-shaped trench groove 109. Thereflow stopper groove 107 is positioned along the U-shaped trench groove109.

A resist mask 108 is selectively formed over the upper surface of theconductive film 106 by use of a lithography technique. The resist mask 8comprises a thick resist mask 118 and a thin resist mask 128. The thickresist mask 118 is positioned in selected regions adjacent to a channelregion 115 which has a rectangle shape. The selected regions also haverectangle shape regions along opposite outsides of the rectangle shapechannel region 115. The thick resist mask 118 may have a thickness ofabout 3 micrometers. The thin resist mask 128 may have a thickness ofabout 0.2–0.7 micrometers.

A first etching process is carried out by use of the thick and thinresist masks 118 and 128 for selectively etching the conductive film 106and the n+-type amorphous silicon film 105. The top conductive film 106may comprise a metal film. The top conductive film 106 may selectivelybe etched by a wet etching process to form source and drain electrodes113 and 114. The n+-type amorphous silicon film 105 may also selectivelybe etched by a dry etching process under a pressure of 10 Pa, at a powerof 1000 W for 60 seconds, wherein source gas flow rate ratios ofSF₆/HCl/He are 100/100/150 sccm to form ohmic contact layers 110 and 111which underlie the source and drain electrodes 113 and 114, therebymaking ohmic contacts between the amorphous silicon film 104 and thesource and drain electrodes 113 and 114.

Subsequently, a plasma ashing process is carried out in the presence ofplasma atmosphere with oxygen flow rate at 400 sccm under a pressure of20 Pa, and an RF power of 1000 W for 120 seconds. This plasma ashingprocess reduces the thickness of the resist mask 8, whereby the thinresist mask 128 is removed whilst the thick resist mask 118 is reducedin thickness, whereby the thickness-reduced resist mask 118 becomes aresidual resist mask 138 which extends on the selected regions adjacentto the channel region 115.

With reference to FIGS. 12A and 12B, the residual resist mask 138 isthen exposed to a steam of a solution which contains an organic solventat 27° C. for 1–3 minutes. This exposure process causes the organicsolvent to osmose into the residual resist mask 138, whereby theresidual resist mask 138 is dissolved and re-flowed, and the residualresist mask 138 becomes a reflow-deformed resist mask 148.

A part of the re-flowed resist mask 148 is dropped into the channelregion 115 and other parts of the re-flowed resist mask 148 are droppedinto the reflow stopper groove 107 which extends in a form of thegenerally U-shape and positioned in the generally U-shaped trench groove109. An inward reflow of the resist mask 148 is dropped into the channelregion 115 and a further inward reflow of the resist mask 148 isrestricted by the channel region 115. An outward reflow of the resistmask 148 is omnidirectional. The outward reflow of the resist mask 148in one direction toward a step-like barrier wall 117 which extendsindirectly over an edge of the gate electrode interconnection 102 isstopped or restricted by the step-like barrier wall 117. The remainingoutward reflow of the resist mask 148 in the remaining three directionstoward the reflow stopper groove 107 is dropped into the reflow stoppergroove 107 and stopped or restricted by the reflow stopper groove 107.Each gap between ends of the reflow stopper groove 107 and the step-likebarrier wall 117 is so narrow as substantially restricting a furtheroutward reflow of the resist mask 148. An external shape or acircumferential shape of the reflow-deformed resist mask 148 provides apattern shape. The external shape or a circumferential shape of thereflow-deformed resist mask 148 is defined by the step-like barrier wall117 and outside edges of the reflow stopper groove 107. The step-likebarrier wall 117 and the reflow stopper groove 107 enable a highlyaccurate control or definition to the pattern shape of thereflow-deformed resist mask 148. As long as the positions of thestep-like barrier wall 117 and the reflow stopper groove 107 are highlyaccurate, the pattern shape of the reflow-deformed resist mask 148 isalso highly accurate. Since the highly accurate positioning of thestep-like barrier wall 117 and the reflow stopper groove 107 isrelatively easy by use of the known techniques, it is also relativelyeasy to obtain the desired highly accurate control or definition to thepattern shape of the reflow-deformed resist mask 148.

With reference to FIGS. 13A and 13B, a second etching process is carriedout by use of the deformed resist mask 148 in combination with thesource and drain electrodes 113 and 114 as combined masks forselectively etching the amorphous silicon film 104, whereby theamorphous silicon film 104 becomes an island layer 124 which has apattern shape which is defined by the deformed resist mask 148 incombination with the source and drain electrodes 113 and 114 as combinedmasks. The used deformed resist mask 148 is then removed, whereby a thinfilm transistor is formed.

The island layer 124 of amorphous silicon underlies the ohmic contactlayers 110 and 111. The island layer 124 is thus electrically connectedto the source and drain electrodes 113 and 114. A parasitic capacitancebetween the gate electrode 102 and the source and drain electrodes 113and 114 depends on the pattern shape of the island layer 124. Since itis possible to obtain a highly accurate control or definition to thepattern shape of the reflow-deformed resist mask 148 or the patternshape of the island layer 124, it is possible to obtain a highlyaccurate control to the parasitic capacitance.

In the above described embodiment, the reflow of the residual resistfilm 138 is caused by exposing the residual resist film 138 to the steamwhich contains the solution containing the organic solvent. Any otherknow methods for causing the re-flow of the resist mask are, of course,available. The re-flow may be caused by applying a heat to the resistmask.

The above novel method is further applicable to deformation to otherpattern film than the resist mask, provided the pattern is allowed to bere-flowed by any available measures.

The above described novel method of the second embodiment may bemodified as follows. FIG. 14A is a fragmentary plan view of a thin filmtransistor of a third step involved in novel sequential fabricationprocesses in a first modification to the second embodiment in accordancewith the present invention. FIG. 14B is a fragmentary cross sectionalelevation view of a thin film transistor shown in FIG. 14A, taken alongan A–A′ line.

The following descriptions will focus on the difference of the firstmodified method from the above novel method of the second embodiment. Inthe above novel method of the second embodiment, the trench groove 109is formed in generally U-shape, so that the trench groove 109incompletely surrounds the gate electrode 102 in the three directionsother than one direction toward the gate electrode interconnection 102,in order to keep the trench groove 109 separate from the gate electrodeinterconnection 102. Further, the trench groove 109 has a depth which isthe same level as the top surface of the insulating substrate 101.Namely, the bottom of the trench groove 109 comprises a part of the topsurface of the insulating substrate 101.

In accordance with this first modification to the above novel method ofthe second embodiment, a trench groove 129 is formed in rectangleannular shape in plan view, so that the trench groove 129 completelysurrounds the gate electrode 102 in all directions, with keeping thetrench groove 129 separate from the gate electrode interconnection 102,because the trench groove 129 has a shallower depth which is upper levelthan the top surface of the insulating substrate 101. Namely, the bottomof the trench groove 109 has an intermediate level of the gateinsulating film 103.

With reference to FIGS. 14A and 14B, the n+-type amorphous silicon film105, the amorphous silicon film 104 and the gate insulating film 103 areselectively etched to form a trench groove 129 which extends in a formof generally rectangle annular shape in plan view. A bottom of thetrench groove 109 has an upper level than a top level of the gateelectrode interconnection 102. The trench groove 129 is generallyrectangle annular shaped, so that the trench groove 129 surrounds therectangle-shaped gate electrode 102 completely in all directions. Thetrench groove 129 is separate from the gate electrode 102 and from thegate electrode interconnection 102. The trench groove 129 extendsoutside the gate electrode 102. The trench groove 129 has an uniformwidth.

An upper surface of the conductive film 106 also has a reflow stoppergroove 127 which extends in a form of generally rectangle annular shapein plan view. The reflow stopper groove 127 extends overlaps thegenerally rectangle annular shaped trench groove 129. The reflow stoppergroove 127 is positioned along the generally rectangle annular shapetrench groove 129.

In he re-flow process, a part of the re-flowed resist mask 158 isdropped into the channel region 115 and other parts of the re-flowedresist mask 158 are dropped into the reflow stopper groove 127 whichextends in a form of the generally rectangle annular shape andpositioned in the generally rectangle annular shape trench groove 129.An inward reflow of the resist mask 158 is dropped into the channelregion 115 and a further inward reflow of the resist mask 158 isrestricted by the channel region 115. An outward reflow of the resistmask 158 is omnidirectional. The outward reflow of the resist mask 158in one direction toward a step-like barrier wall 117 which extendsindirectly over an edge of the gate electrode interconnection 102 isstopped or restricted by the step-like barrier wall 117. The remainingoutward reflow of the resist mask 158 in the remaining three directionstoward the reflow stopper groove 127 is dropped into the reflow stoppergroove 127 and stopped or restricted by the reflow stopper groove 127.An external shape or a circumferential shape of the reflow-deformedresist mask 148 provides a pattern shape. The external shape or acircumferential shape of the reflow-deformed resist mask 158 is definedby the step-like barrier wall 117 and outside edges of the reflowstopper groove 127. The step-like barrier wall 117 and the reflowstopper groove 127 enable a highly accurate control or definition to thepattern shape of the reflow-deformed resist mask 158. As long as thepositions of the step-like barrier wall 117 and the reflow stoppergroove 127 are highly accurate, the pattern shape of the reflow-deformedresist mask 158 is also highly accurate. Since the highly accuratepositioning of the step-like barrier wall 117 and the reflow stoppergroove 127 is relatively easy by use of the known techniques, it is alsorelatively easy to obtain the desired highly accurate control ordefinition to the pattern shape of the reflow-deformed resist mask 158.

THIRD EMBODIMENT

A third embodiment according to the present invention will be describedin detail with reference to the drawings. FIG. 15A is a fragmentary planview of a thin film transistor of a first step involved in novelsequential fabrication processes in a third embodiment in accordancewith the present invention. FIG. 15B is a fragmentary cross sectionalelevation view of a thin film transistor shown in FIG. 15A, taken alongan A–A′ line. FIG. 16A is a fragmentary plan view of a thin filmtransistor of a second step involved in novel sequential fabricationprocesses in a third embodiment in accordance with the presentinvention. FIG. 16B is a fragmentary cross sectional elevation view of athin film transistor shown in FIG. 16A, taken along an A–A′ line. FIG.17A is a fragmentary plan view of a thin film transistor of a third stepinvolved in novel sequential fabrication processes in a third embodimentin accordance with the present invention. FIG. 17B is a fragmentarycross sectional elevation view of a thin film transistor shown in FIG.17A, taken along a B–B′ line. A thin film transistor is formed over aninsulating substrate 201.

With reference to FIGS. 15A and 15B, a bottom conductive film is formedover a top surface of the insulating substrate 201. The bottomconductive film is patterned to form a gate electrode interconnection202. The gate electrode interconnection 202 has a gate electrode 202which has a rectangle shape in plan view. The gate electrode 202 extendsfrom the gate electrode interconnection 202 in a direction perpendicularto a longitudinal direction of the gate electrode interconnection 202.

A gate insulating film 203 is formed over the insulating substrate 201and the gate electrode interconnection 202, and the gate electrode 202.An amorphous silicon film 204 is formed over the upper surface of thegate insulating film 203. An n+-type amorphous silicon film 205 isformed over the upper surface of the amorphous silicon film 204. Aconductive film 206 is entirely formed over the upper surface of then+-type amorphous silicon film 205.

A resist mask 208 is selectively formed over the upper surface of theconductive film 206 by use of a lithography technique. The resist mask208 comprises a thick resist mask 218 and a thin resist mask 228. Thethick resist mask 218 is positioned in selected regions adjacent to achannel region 215 which has a rectangle shape. The selected regionsalso have rectangle shape regions along opposite outsides of therectangle shape channel region 215. The thick resist mask 218 may have athickness of about 3 micrometers. The thin resist mask 228 may have athickness of about 0.2–0.7 micrometers.

A first etching process is carried out by use of the thick and thinresist masks 218 and 228 for selectively etching the conductive film 206and the n+-type amorphous silicon film 205. The top conductive film 206may comprise a metal film. The top conductive film 206 may selectivelybe etched by a wet etching process to form source and drain electrodes213 and 214. The n+-type amorphous silicon film 205 may also selectivelybe etched by a dry etching process under a pressure of 10 Pa, at a powerof 1000 W for 60 seconds, wherein source gas flow rate ratios ofSF₆/HCl/He are 100/100/150 sccm.

As a result of this etching process, the n+-type amorphous silicon film205 and the conductive film 206 are patterned to form a reflow stoppergroove 207 which extends in a form of generally U-shape in plan view.Further, the n+-type amorphous silicon film 205 and the channel region215 are patterned. The patterned n+-type amorphous silicon film 205becomes ohmic contact layers 210 and 211. The patterned conductive film206 becomes source and drain electrodes 213 and 214 adjacent to thechannel region 215 and also dummy source and drain electrodes 233 and234.

Each of the dummy source and drain electrodes 233 and 234 extends in aform of generally L-shape in plan view, so that the paired dummy sourceand drain electrodes 233 and 234 extend in a form of generally U-shapein plan view, provided that the paired dummy source and drain electrodes233 and 234 are separate from each other. In plan view, the paired dummysource and drain electrodes 233 and 234 surround the rectangle-shapedgate electrode 202 in three directions other than a direction toward thegate electrode interconnection 202. The paired dummy source and drainelectrodes 233 and 234 are separated from the paired source and drainelectrodes 213 and 214 by the reflow stopper groove 207. Accordingly,the paired dummy source and drain electrodes 233 and 234 define outsideedges of the reflow stopper groove 207, while the paired source anddrain electrodes 213 and 214 define inside edges of the reflow stoppergroove 207. A bottom of the reflow stopper groove 207 comprises a partof the upper surface of the amorphous silicon film 204.

With reference to FIGS. 16A and 16B, a plasma ashing process is carriedout in the presence of plasma atmosphere with oxygen flow rate at 400sccm under a pressure of 20 Pa, and an RF power of 1000 W for 120seconds. This plasma ashing process reduces the thickness of the resistmask 208, whereby the thin resist mask 228 is removed whilst the thickresist mask 218 is reduced in thickness, whereby the thickness-reducedresist mask 218 becomes a residual resist mask 238 which extends on theselected regions adjacent to the channel region 215.

With reference to FIGS. 17A and 17B, the residual resist mask 238 isthen exposed to a steam of a solution which contains an organic solventat 27° C. for 1–3 minutes. This exposure process causes the organicsolvent to osmose into the residual resist mask 238, whereby theresidual resist mask 238 is dissolved and re-flowed, and the residualresist mask 238 becomes a reflow-deformed resist mask 248.

A part of the re-flowed resist mask 248 is dropped into the channelregion 215 and other parts of the re-flowed resist mask 248 are droppedinto the reflow stopper groove 207 which extends in a form of thegenerally U-shape and positioned in the generally U-shaped trench groove109. An inward reflow of the resist mask 248 is dropped into the channelregion 215 and a further inward reflow of the resist mask 248 isrestricted by the channel region 215. An outward reflow of the resistmask 248 is omnidirectional. The outward reflow of the resist mask 248in one direction toward a step-like barrier wall 217 which extendsindirectly over an edge of the gate electrode interconnection 202 isstopped or restricted by the step-like barrier wall 217. The remainingoutward reflow of the resist mask 248 in the remaining three directionstoward the reflow stopper groove 207 is dropped into the reflow stoppergroove 207 and stopped or restricted by the reflow stopper groove 207. Agap between ends of the paired dummy source and drain electrodes 233 and234 is so narrow as substantially restricting a further outward reflowof the resist mask 248.

An external shape or a circumferential shape of the reflow-deformedresist mask 248 provides a pattern shape. The external shape or acircumferential shape of the reflow-deformed resist mask 248 is definedby the step-like barrier wall 217 and outside edges of the reflowstopper groove 207. The step-like barrier wall 217 and the reflowstopper groove 207 enable a highly accurate control or definition to thepattern shape of the reflow-deformed resist mask 248. As long as thepositions of the step-like barrier wall 217 and the reflow stoppergroove 207 are highly accurate, the pattern shape of the reflow-deformedresist mask 248 is also highly accurate. Since the highly accuratepositioning of the step-like barrier wall 217 and the reflow stoppergroove 207 is relatively easy by use of the known techniques, it is alsorelatively easy to obtain the desired highly accurate control ordefinition to the pattern shape of the reflow-deformed resist mask 248.

A second etching process is carried out by use of the deformed resistmask 248 in combination with the source and drain electrodes 213 and 214as combined masks for selectively etching the amorphous silicon film204, whereby the amorphous silicon film 204 becomes an island layer 224which has a pattern shape which is defined by the deformed resist mask248 in combination with the source and drain electrodes 213 and 214 ascombined masks. The used deformed resist mask 248 is then removed,whereby a thin film transistor is formed.

The island layer 224 of amorphous silicon underlies the ohmic contactlayers 210 and 211. The island layer 224 is thus electrically connectedto the source and drain electrodes 213 and 214. A parasitic capacitancebetween the gate electrode 202 and the source and drain electrodes 213and 214 depends on the pattern shape of the island layer 224. Since itis possible to obtain a highly accurate control or definition to thepattern shape of the reflow-deformed resist mask 248 or the patternshape of the island layer 124, it is possible to obtain a highlyaccurate control to the parasitic capacitance.

In the above described embodiment, the reflow of the residual resistfilm 238 is caused by exposing the residual resist film 238 to the steamwhich contains the solution containing the organic solvent. Any otherknow methods for causing the re-flow of the resist mask are, of course,available. The re-flow may be caused by applying a heat to the resistmask.

The above novel method is further applicable to deformation to otherpattern film than the resist mask, provided the pattern is allowed to bere-flowed by any available measures.

FOURTH EMBODIMENT

A fourth embodiment according to the present invention will be describedin detail with reference to the drawings. FIG. 18A is a fragmentary planview of a thin film transistor of a first step involved in novelsequential fabrication processes in a fourth embodiment in accordancewith the present invention. FIG. 18B is a fragmentary cross sectionalelevation view of a thin film transistor shown in FIG. 18A, taken alonga C–C′ line. FIG. 19A is a fragmentary plan view of a thin filmtransistor of a second step involved in novel sequential fabricationprocesses in a fourth embodiment in accordance with the presentinvention. FIG. 19B is a fragmentary cross sectional elevation view of athin film transistor shown in FIG. 19A, taken along a C–C′ line. FIG.20A is a fragmentary plan view of a thin film transistor of a third stepinvolved in novel sequential fabrication processes in a fourthembodiment in accordance with the present invention. FIG. 20B is afragmentary cross sectional elevation view of a thin film transistorshown in FIG. 20A, taken along a C–C′ line. A thin film transistor isformed over an insulating substrate 201.

With reference to FIGS. 18A and 18B, a bottom conductive film is formedover a top surface of the insulating substrate 201. The bottomconductive film is patterned to form a gate electrode interconnection242 and a dummy gate electrode 252. The gate electrode interconnection242 has a gate electrode 242 which has a generally circular shape with aflat side in plan view. The flat side of the generally circular shapegate electrode 242 is adjacent to and separate from the dummy gateelectrode 252. The gate electrode 242 extends from the gate electrodeinterconnection 242 in a direction perpendicular to a longitudinaldirection of the gate electrode interconnection 242. The flat side ofthe generally circular shape gate electrode 242 is perpendicular to thelongitudinal direction of the gate electrode interconnection 242. Thedummy gate electrode 252 is generally I-shaped or rectangle-shape, sothat the dummy gate electrode 252 is adjacent to and separate from theflat side of the generally circular shape gate electrode 242.

The dummy gate electrode 252 is thus separate from the gate electrode242 and from the gate electrode interconnection 242. One side of thegenerally circular shape gate electrode 242 is connected through anextending part from the gate electrode interconnection 242, wherein theextending part extends in perpendicular to the longitudinal direction ofthe gate electrode interconnection 242. An I-shaped or rectangle-shapedgap is defined between the dummy gate electrode 252 and the flat side ofthe generally circular shape gate electrode 242. The I-shaped gap has anuniform width.

A gate insulating film 203 is formed over the insulating substrate 201and the gate electrode interconnection 242, the gate electrode 242 andthe dummy gate electrode 252, wherein the gate insulating film 203 fillsthe I-shaped gap between the dummy gate electrode 252 and the flat sideof the generally circular shape gate electrode 242. An upper surface ofthe gate insulating film 203 has a groove which extends in a form ofgenerally I-shape in plan view. The groove extends over the I-shaped gapbetween the flat side of the generally circular shape gate electrode 242and the dummy gate electrode 252. The groove in the upper surface of thegate insulating film 203 is thus formed by the I-shaped gap between theflat side of the generally circular shape gate electrode 242 and thedummy gate electrode 252.

An amorphous silicon film 204 is formed over the upper surface of thegate insulating film 203. An upper surface of the amorphous silicon film204 also has a groove which extends in a form of generally I-shape inplan view. The groove extends over the I-shaped groove in the uppersurface of the gate insulating film 203.

An n+-type amorphous silicon film 205 is formed over the upper surfaceof the amorphous silicon film 204. An upper surface of the n+-typeamorphous silicon film 205 also has a groove which extends in a form ofgenerally I-shape in plan view. The groove extends over the I-shapedgroove in the upper surface of the amorphous silicon film 204.

A top conductive film 206 is formed over the upper surface of then+-type amorphous silicon film 205. An upper surface of the topconductive film 206 also has a reflow stopper groove 247 which extendsin a form of generally I-shape in plan view. The reflow stopper groove247 extends over the I-shaped groove in the upper surface of the n+-typeamorphous silicon film 205. The reflow stopper groove 247 is positionedindirectly over the I-shaped gap between the flat side of the generallycircular shape gate electrode 242 and the dummy gate electrode 252.

A resist mask 208 is selectively formed over the upper surface of thetop conductive film 206 by use of a lithography technique. The resistmask 208 comprises a thick resist mask 258 and a thin resist mask 268.The thick resist mask 258 is positioned in selected regions adjacent toa channel region 255 which has a partial circle shape or C-shape. Theselected regions also have rectangle shape regions along oppositeoutsides of the rectangle shape channel region 255. The thick resistmask 258 may have a thickness of about 3 micrometers. The thin resistmask 268 may have a thickness of about 0.2–0.7 micrometers.

A first etching process is carried out by use of the thick and thinresist masks 18 and 28 for selectively etching the top conductive film206 and the n+-type amorphous silicon film 205. The top conductive film206 may comprise a metal film. The top conductive film 206 mayselectively be etched by a wet etching process to form source and drainelectrodes 253 and 254. The n+-type amorphous silicon film 205 may alsoselectively be etched by a dry etching process under a pressure of 10Pa, at a power of 1000 W for 60 seconds, wherein source gas flow rateratios of SF₆/HCl/He are 100/100/150 sccm to form ohmic contact layers250 and 251 which underlie the source and drain electrodes 253 and 254,thereby making ohmic contacts between the amorphous silicon film 204 andthe source and drain electrodes 253 and 254. As a result, the channelregion 255, which has a partial circle shape or C-shape, is defined.

With reference to FIGS. 19A and 19B, a plasma ashing process is carriedout in the presence of plasma atmosphere with oxygen flow rate at 400sccm under a pressure of 20 Pa, and an RF power of 1000 W for 120seconds. This plasma ashing process reduces the thickness of the resistmask 208, whereby the thin resist mask 268 is removed whilst the thickresist mask 258 is reduced in thickness, whereby the thickness-reducedresist mask 258 becomes a residual resist mask 278 which extends on theselected region which corresponds to a circular-shaped island portion ofthe drain electrode 254. The selected region, on which the residualresist mask 278 remains, is surrounded by the C-shaped or partiallycircle shaped channel region 255.

With reference to FIGS. 20A and 20B, the residual resist mask 278 isthen exposed to a steam of a solution which contains an organic solvent.This exposure process causes the organic solvent to osmose into theresidual resist mask 278, whereby the residual resist mask 278 isdissolved and re-flowed, and the residual resist mask 278 becomes areflow-deformed resist mask 288.

A part of the re-flowed resist mask 288 is dropped into the C-shapedchannel region 255 and other part of the re-flowed resist mask 288 isdropped into the reflow stopper groove 247 which extends in a form ofthe generally I-shape and positioned indirectly over the I-shaped gapbetween the gate electrode 242 and the dummy gate electrode 252. Noinward reflow of the resist mask 288 is caused. An outward reflow of theresist mask 288 is omnidirectional. The outward reflow of the resistmask 288 is dropped into the C-shaped channel region 255 and theI-shaped reflow stopper groove 247 and stopped or restricted by thereflow stopper groove 247 and the C-shaped channel region 255. Anexternal shape or a circumferential shape of the reflow-deformed resistmask 48 provides a pattern shape. The external shape or acircumferential shape of the reflow-deformed resist mask 48 is almostdefined by the outside edge of the C-shaped channel region 255 and thereflow stopper groove 247. The outside edge of the C-shaped channelregion 255 and the reflow stopper groove 247 enable a highly accuratecontrol or definition to the pattern shape of the reflow-deformed resistmask 288. As long as the definitions of the outside edge of the C-shapedchannel region 255 and the reflow stopper groove 247 are highlyaccurate, the pattern shape of the reflow-deformed resist mask 288 isalso highly accurate. Since the highly accurate definitions of theoutside edge of the C-shaped channel region 255 and the reflow stoppergroove 247 are relatively easy by use of the known techniques, it isalso relatively easy to obtain the desired highly accurate control ordefinition to the pattern shape of the reflow-deformed resist mask 288.

A second etching process is carried out by use of the deformed resistmask 288 in combination with the source and drain electrodes 253 and 254as combined masks for selectively etching the amorphous silicon film204, whereby the amorphous silicon film 204 becomes an island layer 264which has a pattern shape which is defined by the deformed resist mask288 in combination with the source and drain electrodes 253 and 254 ascombined masks. The used deformed resist mask 288 is then removed,whereby a thin film transistor is formed.

The island layer 264 of amorphous silicon underlies the ohmic contactlayers 250 and 251. The island layer 264 is thus electrically connectedto the source and drain electrodes 253 and 254. A parasitic capacitancebetween the gate electrode 242 and the source and drain electrodes 253and 254 depends on the pattern shape of the island layer 264. Since itis possible to obtain a highly accurate control or definition to thepattern shape of the reflow-deformed resist mask 288 or the patternshape of the island layer 264, it is possible to obtain a highlyaccurate control to the parasitic capacitance.

In the above described embodiment, the reflow of the residual resistfilm 278 is caused by exposing the residual resist film 278 to the steamwhich contains the solution containing the organic solvent. Any otherknow methods for causing the re-flow of the resist mask are, of course,available. The re-flow may be caused by applying a heat to the resistmask.

The above novel method is further applicable to deformation to otherpattern film than the resist mask, provided the pattern is allowed to bere-flowed by any available measures.

In accordance with this novel method, the channel region 255, the sourceelectrode 253 are partially circle shape or C-shape. It is, however,possible to modify this shape into the rectangle, square and otherpolygonal shape, provided that the outward reflow of the resist film isrestricted by the channel region and the reflow stopper groove.

FIRST EMBODIMENT

A fifth embodiment according to the present invention will be describedin detail with reference to the drawings. FIG. 21A is a fragmentary planview of a thin film transistor of a first step involved in novelsequential fabrication processes in a fifth embodiment in accordancewith the present invention. FIG. 21B is a fragmentary cross sectionalelevation view of a thin film transistor shown in FIG. 21A, taken alongan E–E′ line. FIG. 22A is a fragmentary plan view of a thin filmtransistor of a second step involved in novel sequential fabricationprocesses in a fifth embodiment in accordance with the presentinvention. FIG. 22B is a fragmentary cross sectional elevation view of athin film transistor shown in FIG. 22A, taken along an E–E′ line. FIG.23A is a fragmentary plan view of a thin film transistor of a third stepinvolved in novel sequential fabrication processes in a fifth embodimentin accordance with the present invention. FIG. 23B is a fragmentarycross sectional elevation view of a thin film transistor shown in FIG.23A, taken along an E–E′ line. FIG. 24A is a fragmentary plan view of athin film transistor of a fourth step involved in novel sequentialfabrication processes in a fifth embodiment in accordance with thepresent invention. FIG. 24B is a fragmentary cross sectional elevationview of a thin film transistor shown in FIG. 24A, taken along an E–E′line. A thin film transistor is formed over an insulating substrate 401.

With reference to FIGS. 21A and 21B, a bottom conductive film is formedover a top surface of the insulating substrate 401. The bottomconductive film is patterned to form a gate electrode interconnection402. The gate electrode interconnection 402 has a gate electrode 402which has an octagonal shape in plan view. The gate electrode 402extends from the gate electrode interconnection 402 in a directionperpendicular to a longitudinal direction of the gate electrodeinterconnection 402.

A gate insulating film 403 is formed over the insulating substrate 401and the gate electrode interconnection 402, and the gate electrode 402.An amorphous silicon film 404 is formed over the upper surface of thegate insulating film 403. An n+-type amorphous silicon film 405 isformed over the upper surface of the amorphous silicon film 404. Aconductive film 406 is entirely formed over the upper surface of then+-type amorphous silicon film 405.

A resist mask 408 is selectively formed over the upper surface of theconductive film 206 by use of a lithography technique. The resist mask408 comprises a thick resist mask 458 and a thin resist mask 468. Thethick resist mask 458 is positioned in a selected region which is overthe octagonal shape gate electrode 402. The selected region is anoctagonal shape region. The thick resist mask 458 may have a thicknessof about 3 micrometers. The thin resist mask 468 may have a thickness ofabout 0.2–0.7 micrometers.

A first etching process is carried out by use of the thick and thinresist masks 458 and 468 for selectively etching the conductive film 406and the n+-type amorphous silicon film 405. The top conductive film 406may comprise a metal film. The top conductive film 406 may selectivelybe etched by a wet etching process to form source and drain electrodes453 and 454. The n+-type amorphous silicon film 405 may also selectivelybe etched by a dry etching process under a pressure of 10 Pa, at a powerof 1000 W for 60 seconds, wherein source gas flow rate ratios ofSF₆/HCl/He are 100/100/150 sccm.

As a result of this etching process, the n+-type amorphous silicon film405 and the conductive film 406 are patterned to form a reflow stoppergroove 407 which extends in a form of generally U-shape in plan view.Further, the n+-type amorphous silicon film 405 and the channel region455 are patterned. The patterned n+-type amorphous silicon film 405becomes ohmic contact layers 450 and 451. The patterned conductive film406 becomes source and drain electrodes 453 and 454 adjacent to thechannel region 455.

The source electrode 453 extends in a form of combined modified T-shapeand octagonal island shape. Namely, the source electrode 453 includes anoctagonal shape island portion and a modified T-shaped portion connectedwith the octagonal shape island portion. The octagonal shape islandportion is surrounded by an octagonal shape annular channel region 455.The drain electrode 454 includes an octagonal shape annular surroundingportion which surrounds the octagonal shape island portion of the sourceelectrode 453. The octagonal shape annular surrounding portion of thedrain electrode 454 is separate by the octagonal shape annular channelregion 455 from the octagonal shape island portion of the sourceelectrode 453. The octagonal shape annular surrounding portion of thedrain electrode 454 has an opening side, so that the octagonal shapeannular surrounding portion incompletely surrounds the octagonal shapeisland portion of the source electrode 453. The modified T-shapedportion of the source electrode 453 extends through the opening side tothe octagonal shape island portion of the source electrode 453. Themodified T-shaped portion of the source electrode 453 also extendsoutside the opening side of the octagonal shape annular surroundingportion of the drain electrode 454.

With reference to FIGS. 22A and 22B, a plasma ashing process is carriedout in the presence of plasma atmosphere with oxygen flow rate at 400sccm under a pressure of 20 Pa, and an RF power of 1000 W for 120seconds. This plasma ashing process reduces the thickness of the resistmask 408, whereby the thin resist mask 468 is removed whilst the thickresist mask 458 is reduced in thickness, whereby the thickness-reducedresist mask 458 becomes a first residual resist mask 478 which extendson the octagonal shape island portion of the source electrode 453 and asecond residual resist mask 479 which extends on an inside peripheralregion of the octagonal shape annular surrounding portion of the drainelectrode 454.

With reference to FIGS. 23A and 23B, the residual resist masks 478 and479 are then exposed to a steam of a solution which contains an organicsolvent at 27° C. for 1–3 minutes. This exposure process causes theorganic solvent to osmose into the residual resist masks 478 and 479,whereby the residual resist masks 478 and 479 are dissolved andre-flowed, and the residual resist masks 478 and 479 become areflow-deformed resist mask 488.

A part of the re-flowed resist mask 488 is dropped into the channelregion 455, and a part of the dropped re-flowed resist mask 488 in thechannel region 455 is further re-flowed out of the opening side of theoctagonal shape annular surrounding portion of the drain electrode 454.This further outward re-flow from the opening side is, however,restricted by the modified T-shaped portion of the source electrode 453.The reflow stopper groove 407, thus, comprises the channel region 455and a region between the opening side of the octagonal shape annularsurrounding portion of the drain electrode 454 and the modified T-shapedportion of the source electrode 453.

As a modification, if a opening size of the opening side of theoctagonal shape annular surrounding portion of the drain electrode 454is too narrow as effectively restricting the further outward re-flow, itis possible to modify the T-shaped portion of the source electrode 453into an I-shape which connects with the octagonal shape island portionof the source electrode 453.

An external shape or a circumferential shape of the reflow-deformedresist mask 488 provides a pattern shape. The external shape or acircumferential shape of the reflow-deformed resist mask 488 is definedby the reflow stopper groove 407 including the channel region 455. Thereflow stopper groove 407 enable a highly accurate control or definitionto the pattern shape of the reflow-deformed resist mask 488. As long asthe reflow stopper groove 207 is highly accurate, the pattern shape ofthe reflow-deformed resist mask 488 is also highly accurate. Since thehighly accurate positioning of the reflow stopper groove 407 isrelatively easy by use of the known techniques, it is also relativelyeasy to obtain the desired highly accurate control or definition to thepattern shape of the reflow-deformed resist mask 488.

A second etching process is carried out by use of the deformed resistmask 488 in combination with the source and drain electrodes 453 and 454as combined masks for selectively etching the amorphous silicon film404, whereby the amorphous silicon film 404 becomes an island layer 464which has a pattern shape which is defined by the deformed resist mask488 in combination with the source and drain electrodes 453 and 454 ascombined masks.

The island layer 464 of amorphous silicon underlies the ohmic contactlayers 450 and 451. The island layer 464 is thus electrically connectedto the source and drain electrodes 453 and 454. A parasitic capacitancebetween the gate electrode 402 and the source and drain electrodes 453and 454 depends on the pattern shape of the island layer 464. Since itis possible to obtain a highly accurate control or definition to thepattern shape of the reflow-deformed resist mask 488 or the patternshape of the island layer 464, it is possible to obtain a highlyaccurate control to the parasitic capacitance.

With reference to FIGS. 24A and 24B, the used deformed resist mask 488is then removed, whereby a thin film transistor is formed. A passivationfilm 423 is formed. Contact holes 490 and 491 are formed in thepassivation film 423. A pixel electrode 492 and a gate terminalelectrode 493 are formed.

In the above described embodiment, the reflow of the residual resistmasks is caused by exposing the residual resist masks to the steam whichcontains the solution containing the organic solvent. Any other knowmethods for causing the re-flow of the resist mask are, of course,available. The re-flow may be caused by applying a heat to the resistmask.

The above novel method is further applicable to deformation to otherpattern film than the resist mask, provided the pattern is allowed to bere-flowed by any available measures.

The above described novel method of the fifth embodiment may be modifiedas follows. FIG. 25A is a fragmentary plan view of a thin filmtransistor of a third step involved in novel sequential fabricationprocesses in a first modification to the fifth embodiment in accordancewith the present invention. FIG. 25B is a fragmentary cross sectionalelevation view of a thin film transistor shown in FIG. 25A, taken alongan F–F′ line.

The following descriptions will focus on the difference of the firstmodified method from the above novel method of the fifth embodiment. Inthe above novel method of the fifth embodiment, the gate electrode 402and the gate electrode interconnection 402 have the same level and thesame thickness. The re-flow stopper groove 407 also comprises thechannel region 455 and the region between the opening side to theoctagonal shape island portion of the source electrode 453 and themodified T-shaped portion of the source electrode 453. In this firstmodification, however, the octagonal shape gate electrode 402 isthickness-reduced except for an outside peripheral edge thereof. Theoutside peripheral edge of the octagonal shape gate electrode 402 havethe same thickness as the gate electrode interconnection 402. A step isformed at a boundary between the thickness reduced region and theoutside peripheral edge. This step of the gate electrode 402 causes astep of the modified T-shaped portion of the source electrode 453 and astep of the octagonal shape annular surrounding portion of the drainelectrode 454. The step of the modified T-shaped portion of the sourceelectrode 453 and the step of the octagonal shape annular surroundingportion of the drain electrode 454 serve as a reflow stopper wall. Inthis case, a peripheral edge of the reflow stopper groove 407 is definedby the step of the modified T-shaped portion of the source electrode 453and the step of the octagonal shape annular surrounding portion of thedrain electrode 454.

In this modification, the step of the modified T-shaped portion of thesource electrode 453 and the step of the octagonal shape annularsurrounding portion of the drain electrode 454 are formed by thethickness-reduced portion of the gate electrode 402. It is alternativelypossible that a recessed portion is formed in the substrate 401, whereina step is formed on the peripheral edge of the recessed portion.

Alternatively, the above described novel method of the fifth embodimentmay be modified as follows. FIG. 26A is a fragmentary plan view of athin film transistor of a third step involved in novel sequentialfabrication processes in a second modification to the fifth embodimentin accordance with the present invention. FIG. 26B is a fragmentarycross sectional elevation view of a thin film transistor shown in FIG.26A, taken along an F–F′ line.

The following descriptions will focus on the difference of the secondmodified method from the above novel method of the fifth embodiment. Inthe above novel method of the fifth embodiment, the gate electrode 402and the gate electrode interconnection 402 have the same level and thesame thickness. The re-flow stopper groove 407 also comprises thechannel region 455 and the region between the opening side to theoctagonal shape island portion of the source electrode 453 and themodified T-shaped portion of the source electrode 453. In this firstmodification, however, the octagonal shape gate electrode 402 has athickness-reduced region 495. A step is formed at a peripheral edge ofthe thickness-reduced region 495. This step of the gate electrode 402causes a groove extending over the channel region 455 and the modifiedT-shaped portion of the source electrode 453. In this case, a peripheraledge of the reflow stopper groove 407 is defined by the channel region455 and the groove positioned over the thickness-reduced region 495 ofthe gate electrode 402.

In this modification, the groove is formed by the thickness-reducedregion 495 of the gate electrode 402. It is alternatively possible thata recessed portion is formed in the substrate 401, wherein the groove isformed on the peripheral edge of the recessed portion.

Further, alternatively, the above described novel method of the fifthembodiment may be modified as follows. FIG. 27A is a fragmentary planview of a thin film transistor of a third step involved in novelsequential fabrication processes in a third modification to the fifthembodiment in accordance with the present invention. FIG. 27B is afragmentary cross sectional elevation view of a thin film transistorshown in FIG. 27A, taken along an F–F′ line.

The following descriptions will focus on the difference of the thirdmodified method from the above novel method of the fifth embodiment. Thesource electrode 453 extends in a form of octagonal island shape.Namely, the source electrode 453 includes an octagonal shape islandportion. The octagonal shape island portion is surrounded by anoctagonal shape annular channel region 455. The drain electrode 454includes an octagonal shape annular surrounding portion which surroundscompletely the octagonal shape island source electrode 453. Theoctagonal shape annular surrounding portion of the drain electrode 454is separate by the octagonal shape annular channel region 455 from theoctagonal shape island source electrode 453. The octagonal shape annularsurrounding portion of the drain electrode 454 has no opening side, sothat the octagonal shape annular surrounding portion completelysurrounds the octagonal shape island source electrode 453. In this case,the reflow stopper groove 407 extends on the channel region 455.

A passivation film 423 is formed. A contact hole 497 is formed in thepassivation film 423, so that the contact hole 497 is positioned overthe octagonal shape island portion of the source electrode 453. A pixelelectrode 496 is formed on the passivation film 423, wherein the pixelelectrode 496 is connected through the contact hole 497 to the octagonalshape island source electrode 453.

In the foregoing embodiments, the selected region, on which the residualresist film remains, is preferably decided. The position of the selectedregion is optional, provided that the selected region is positionedinside the reflow stopper groove, so that the outward reflow of theresist film is stopped or restricted by the reflow stopper grooveextending outside the resist film.

As modifications to the foregoing embodiments, the above re-flow stoppergroove may be formed by forming a groove or a level-down region on anupper surface of the substrate.

Although the invention has been described above in connection withseveral preferred embodiments therefor, it will be appreciated thatthose embodiments have been provided solely for illustrating theinvention, and not in a limiting sense. Numerous modifications andsubstitutions of equivalent materials and techniques will be readilyapparent to those skilled in the art after reading the presentapplication, and all such modifications and substitutions are expresslyunderstood to fall within the true scope and spirit of the appendedclaims.

1. A semiconductor device including gate, source and drain electrodes,dummy source and drain electrodes, a layered structure over a substrate,and at least a groove, wherein said dummy source and drain electrodesare positioned outside said source and drain electrodes, and said grooveseparates said source and drain electrodes from said dummy source anddrain electrodes, and, wherein said groove extends outside at least aselected region on said layered-structure, and said selected regionbeing adjacent to a channel region, and said groove extends outside ofsaid gate electrode in plan view and said groove is separate from saidgate electrode in plan view.
 2. The semiconductor device as claimed inclaim 1, wherein said groove surrounds said gate electrode incompletely.3. The semiconductor device as claimed in claim 1, wherein said groovesurrounds said gate electrode completely.
 4. The semiconductor device asclaimed in claim 3, wherein said groove extends in an annular form. 5.The semiconductor device as claimed in claim 1, wherein said grooveextends adjacent to and parallel to a flat side of said gate electrode.